Professor David Curtis
MEng (hons), PhD
Advanced Manufacturing Research Centre
Professor of Subtractive Manufacturing
d.t.curtis@sheffield.ac.uk
Factory of the Future, Advanced Manufacturing Park
Full contact details
Professor David Curtis
Advanced Manufacturing Research Centre
Factory of the Future, Advanced Manufacturing Park
Wallis Way, Catcliffe
Rotherham
S60 5TZ
Advanced Manufacturing Research Centre
Factory of the Future, Advanced Manufacturing Park
Wallis Way, Catcliffe
Rotherham
S60 5TZ
- Profile
-
Professor David Curtis is the Head of Capability for Subtractive Manufacturing at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) and holds a Personal Chair in Subtractive Manufacturing. He is a nationally recognised authority on machining science and technology translation, serving as the National Chair of the HVM Catapult’s Technology Special Purpose Group (T-SPG) for Subtractive Manufacturing. In this role, he leads the technology roadmapping effort, strategic foresighting, and research and innovation pipeline to ensure the UK remains a global leader in high-value subtractive manufacturing.
David graduated with an MEng in Mechanical Engineering from the University of Birmingham in 2005 (including a Year in Industry), where he also completed his EPSRC and Rolls-Royce-funded PhD on advanced point grinding technology for aeroengine turbine discs. Joining the AMRC in 2009, he progressed from Project Engineer to Technical Fellow, systematically establishing and scaling world-class research portfolios in Abrasive Machining, Emerging Machining Technology, Machining Science, and Complex Commodity Manufacturing (Aerofoils, Gears, and Transmissions). He is also the UK pioneer for translational research in the machining of Ceramic Matrix Composites (CMCs), successfully bridging low-TRL fundamental material science with high-TRL factory-floor deployment.
As the capability lead for subtractive manufacturing processes and technologies, David directs the unified institutional machining capability, bridging fundamental academic research with immediate industrial exploitation for global Tier-1 aerospace, defense, and energy partners. He is deeply committed to nurturing the next generation of engineering talent; he serves as the AMRC Postgraduate Research (PGR) Lead, directing the doctoral training and research culture for the AMRC's PhD cohort, and is the Co-Director of Innovation for the EPSRC Centre for Doctoral Training in Machining, Assembly, and Digital Engineering for Manufacturing.
- Qualifications
-
MEng (hons) in Mechanical Engineering, PhD in Mechanical Engineering
- Research interests
-
Professor Curtis’s research lies at the intersection of fundamental machining science and industrial implementation. His work aims to deliver productivity, resilience, and sustainability to the high-value manufacturing sector. His core research interests are structured across three strategic pillars:
Subtractive Processes & Machining Physics
- Advanced Abrasive Processes & Point Grinding: Developing high-performance grinding capabilities, including electroplated superabrasive (cBN) tool surface texture evolution, grit morphology effects, and wheel regenerative dynamics in surface grinding.
- Machining of Advanced & Exotic Materials: Investigating tool-workpiece interactions during the machining of hard-to-cut alloys, superalloys (Inconel 718, titanium), and Ceramic Matrix Composites (CMCs). This includes studying chip formation and the wear mechanisms of advanced tool materials like SiAlON and whisker-reinforced ceramics.
- Non-Conventional & Precision Machining: Advancing non-conventional material removal methods, such as Wire Electrical Discharge Machining (WEDM), and their application in the micro-manufacturing of complex miniature commodities, including gears and aerofoils.
Subtractive Technology & Digitalisation
- Zero-Defect Subtractive Manufacturing: Sizing and characterisation of microstructural surface integrity features and detecting thermally-induced metallurgical defects using non-destructive evaluation (NDE) techniques such as X-ray diffraction (XRD).
- Digital Subtractive Manufacturing & Digital Twins: Developing data-driven modelling techniques, including neural networks for machine tool feedrate and cycle time prediction, and real-time model-based simulations for closed-loop machining control.
- Hybrid Manufacturing Systems: Advancing additive-subtractive interfaces, specifically evaluating mechanical properties and shielding effectiveness in Direct Energy Deposition (DED) of reactive materials (e.g., Ti-6Al-4V, 15-5 PH stainless steel).
Subtractive Implementation & Translational Strategy
- Strategic Foresighting & Roadmapping: Leading the UK’s national roadmapping and strategic investment pipeline for high-value machining in his role as Chair of the HVM Catapult’s Subtractive Manufacturing Technology Special Purpose Group (Tech-SPG).
- Industrial Technology Translation: Developing robust translational pathways to scale fundamental machining science (low TRL) into reliable, high-TRL industrial applications for major aerospace, defence, and energy partners.
- Workforce Development & Doctoral Education: Presiding over doctoral training and research culture as PGR Lead for the AMRC and directing innovation within the EPSRC CDT in Machining, Assembly, and Digital Engineering (MADE4Manufacturing).
- Publications
-
Journal articles
- Rapid on-machine cutting tool geometry characterisation using 3D laser line scanners. Procedia CIRP, 141, 502-507.
- Intelligent real-time tool life prediction for a digital twin framework. Journal of Intelligent Manufacturing. View this article in WRRO
- Application of low frequency vibration to the turning of ultra-high molecular weight polyethylene. Advanced Manufacturing: Polymer & Composites Science, 11(1). View this article in WRRO
- Assessment of cutting force coefficient identification methods and force models for variable pitch and helix bull-nose tools. CIRP Journal of Manufacturing Science and Technology, 55, 210-223.
- Digital framework for metallic subtractive process planning: Liger optimisation case study. Procedia CIRP, 130, 1358-1363. View this article in WRRO
- Non-destructive on-machine inspection of machining-induced deformed layers. CIRP Journal of Manufacturing Science and Technology, 52, 296-306. View this article in WRRO
- Non-destructive X-ray diffraction surface integrity inspection of an aeroengine component. Procedia CIRP, 123, 357-362.
- Vibration Signal-Based Tool Condition Monitoring Using Regularized Sensor Data Modeling and Model Frequency Analysis. IEEE Transactions on Instrumentation and Measurement, 73, 1-13.
- Tool life and wear mechanisms of CVD coated and uncoated SiAlON ceramic milling inserts when machining aged Inconel 718. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 238(6-7), 1069-1083. View this article in WRRO
- Unsupervised Detection of Tool Breakage: A Novel Approach Based on Time and Sensor Domain Data Analysis. IEEE Transactions on Instrumentation and Measurement, 72, 1-13.
- Hybrid simultaneous laser- and ultrasonic-assisted machining of Ti-6Al-4V alloy. The International Journal of Advanced Manufacturing Technology, 125(3-4), 1903-1916. View this article in WRRO
- Resource-efficient performance testing of metalworking fluids utilizing single-point milling. Tribology - Materials, Surfaces & Interfaces, 17(1), 34-47. View this article in WRRO
- Evolution of electroplated cBN tool surface texture parameters during point grinding. Journal of Manufacturing Science and Engineering, 144(12). View this article in WRRO
- Rapid non-destructive sizing of microstructural surface integrity features using x-ray diffraction. NDT & E International, 131. View this article in WRRO
- Characterisation of mechanical properties of 15-5PH stainless steel manufactured through direct energy deposition. CIRP Journal of Manufacturing Science and Technology, 38, 172-185.
- Productivity enhancement of aircraft turbine disk using a two-step strategy based on tool-path planning and NC-code optimization. Metals, 12(4).
- Increased shielding of a direct energy deposition process to enable deposition of reactive materials; an investigation into deposition of 15-5 PH stainless steel, Inconel 718 and Ti-6Al-4V.. CIRP Journal of Manufacturing Science and Technology, 36, 227-235. View this article in WRRO
- An alternative wheel regenerative mechanism in surface grinding : distributed grit dullness captured by specific energy waves. Mechanical Systems and Signal Processing, 162. View this article in WRRO
- An evaluation of non-destructive methods for detection of thermally-induced metallurgical machining defects. Procedia CIRP, 108, 7-12.
- Machining cycle time prediction : data-driven modelling of machine tool feedrate behavior with neural networks. Robotics and Computer-Integrated Manufacturing, 75. View this article in WRRO
- Chip formation and wear mechanisms of SiAlON and whisker-reinforced ceramics when turning Inconel 718. Wear, 486-487. View this article in WRRO
- Machining Digital Twin using real-time model-based simulations and lookahead function for closed loop machining control. The International Journal of Advanced Manufacturing Technology, 117(11-12), 3615-3629. View this article in WRRO
- Applying experimental micro-tool wear measurement techniques to industrial environments. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 235(10), 1588-1601. View this article in WRRO
- Impact of grinding wheel specification on surface integrity and residual stress when grinding Inconel 718. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 235(10), 1668-1681.
- Editorial for the special issue on Machining Science. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 235(10), 1531-1532.
- An investigation of additively manufactured coolant nozzles for cylindrical grinding applications and progression to high stock removal. Procedia CIRP, 101, 162-165.
- Work holding assessment of an UV adhesive and fixture design method. The International Journal of Advanced Manufacturing Technology, 106(1-2), 741-752.
- Protocol for tool wear measurement in micro-milling. Wear, 420-42, 54-67. View this article in WRRO
- An experimental study of the effects of dressing parameters on the topography of grinding wheels during roller dressing. Journal of Manufacturing Processes, 31, 348-355. View this article in WRRO
- Electrochemical superabrasive machining of a nickel-based aeroengine alloy using mounted grinding points. CIRP Annals, 58(1), 173-176.
- Profiled Superabrasive Grinding Wheels for the Machining of a Nickel Based Superalloy. CIRP Annals, 56(1), 335-338.
- Influence of different lubrication strategies on surface quality and geometric accuracy in incremental sheet forming of stainless steel. The International Journal of Advanced Manufacturing Technology.
- The Recycling and Reuse of High-Value Abrasively Machined Feedstock Materials: A Review. Journal of Manufacturing and Materials Processing, 10(2), 62-62.
- Subtractive Manufacturing of Hazardous Materials: A Review. Safety, 11(4), 112-112.
Conference proceedings
- The effects of rosette tool geometry on the rotational vibration-assisted incremental sheet forming process. Journal of Physics: Conference Series, Vol. 3104(1). Munich, Germany, 7 July 2025 - 7 July 2025. View this article in WRRO
- Evolution of surface quality in micromilling Ti-6Al-4V alloy with increasing machined length. Procedia CIRP, Vol. 123 (pp 221-226). Bremen, Germany, 15 May 2024 - 15 May 2024. View this article in WRRO
- Power Skiving Tool Offsets and the Feasibility of Using a Calculator for Manipulating the Resulting Geometry. American Gear Manufacturers Association Fall Technical Meeting 2023 Ftm 2023
- An investigation into the challenges of the point grinding machining process. Procedia CIRP, Vol. 101 (pp 190-193). Virtual conference, 24 May 2021 - 24 May 2021. View this article in WRRO
- Tool Coatings and their Influence on the Length of Steady-State Wear Region for Micro End Mills. Extended Abstracts from the 2019 STLE Tribology Frontiers Conference. Chicago, IL, USA, 21 October 2019 - 23 October 2019.
- An analytical study of wheel regeneration in surface grinding. Procedia CIRP, Vol. 82 (pp 214-219). Sheffield, UK, 13 June 2019 - 13 June 2019. View this article in WRRO
- The Application of Wire Electrical Discharge Machining (WEDM) in the Prototyping of Miniature Brass Gears. Procedia CIRP, Vol. 77 (pp 642-645). Budapest, Hungary, 25 June 2018 - 25 June 2018. View this article in WRRO
- The influence of abrasive grit morphology on wheel topography and grinding performance. Procedia CIRP, Vol. 77 (pp 239-242). Budapest, Hungary, 25 June 2018 - 25 June 2018. View this article in WRRO
- Evaluation of Workpiece Surface Integrity Following Point Grinding of Advanced Titanium and Nickel Based Alloys. Procedia CIRP, Vol. 45 (pp 47-50)
- Production of complex mounting slots in turbine disks using novel machining techniques. 3rd CIRP conference on high performance cutting
- Performance of electroplated cbn grinding points machining udimet 720. 10th International Symposium on Advanced Abrasive Technology (ISAAT)
- In-process electro discharge dressing (IEDD) of metal bonded superabrasive grinding wheels. Proceedings of the 15th International Symposium on Electromachining Isem 2007 (pp 591-596)
Patents
- Component manufacturing using a grinding tool following a trochoidal path. GB2579784B Appl. 08 Jul 2020.
- Grinding cylindrical bores. EP3659746A1 Appl. 03 Jun 2020.
- Manufacturing method. US11267096B2 Appl. 18 Jun 2020.
- Grinding cylindrical bores. US20200156202A1 Appl. 21 May 2020.
- Mold assemblies of the fastening for the method for the workpiece of machining operations and for this workpiece. CN109514747A Appl. 26 Mar 2019.
- Method and an assembly. US20190084104A1 Appl. 21 Mar 2019.
- Grinding cylindrical bores. GB201818823D0 Appl. 02 Jan 2019.
- A method and an assembly. GB201714976D0 Appl. 01 Nov 2017.
- A method of securing a workpiece for a machining operation and a mould assembly for such a workpiece. EP3456465A3 Appl. 01 Jan 1970.
- Surface assessment. EP4293448A1 Appl. 01 Jan 1970.
- Surface Assessment. GB202208573D0 Appl. 01 Jan 1970.
- Surface Assessment. US20250173957A9 Appl. 01 Jan 1970.
Reports
- Power Skiving - A Step Changing Manufacturing Process Applicable to Multifunctional 5-Axis Machine Tools
Preprints
- Rapid on-machine cutting tool geometry characterisation using 3D laser line scanners. Procedia CIRP, 141, 502-507.
- Research group
-
Machining
- Grants
-
- STAR: Subtractive of spherical Transferred ARc directed energy deposition for aerospace - 10141989 - Innovate UK
- EPSRC Centre for Doctoral Training in Machining, Assembly, and Digital Engineering for Manufacturing (MADE4Manufacturing) - EP/Y010701/1 EP/Y034759/1 - EPSRC
- MUSIC - Manufacturing Unequalled by Sustainable Innovation & Cost - 10052752 - ATI
- Autonomous Robust & Rapid Processes for the Machining of Aerospace Specific Parts & Components - 10052735 - ATI
- Rotational Vibration Assisted Increment Sheet Forming by Novel Tooling (RV-ISF) - EP/W010089/1 - EPSRC
- Metallic Aerospace Structures Technologies for Ecosocial Return - 103040 - ATI
- CMC Development, Manufacturability and Repairability (CERCOMPUK) - 113344 - ATI
- The University of Sheffield and Cutting & Wear Resistant Developments Limited - 511793 - Innovate UK KTP
- TRANSCEND - TRANsmission Supply Chain Excellence for Next generation Dual clutch technologies - 113061 - APC
- Manufacturing Portfolio Project 1: High Performance Rotating Components - 113084 - ATI
- Materials, Manufacturing and Oils Technologies for High Power Gearbox systems (MAMOTH PGB) - 113046 - ATI
- SAMULET II Project 1: Tighter Specification Aerofoils - ATI
- SAMULET II Project 2: High Performance Shaft Machining - ATI
- The SAMULET Programme: High Productivity Technology and Methods: Project 6 (6.2.2) - 110025 - Innovate UK